CN114786936A

CN114786936A - Method for manufacturing a wind turbine blade

Info

Publication number: CN114786936A
Application number: CN202080087903.1A
Authority: CN
Inventors: B·奥尔森; Y·C·V·特朗; C·N·S·科尔费尔特; D·彼得森; A·H·汤姆森
Original assignee: Siemens Gamesa Renewable Energy AS
Current assignee: Siemens Gamesa Renewable Energy AS
Priority date: 2019-12-19
Filing date: 2020-12-10
Publication date: 2022-07-22
Also published as: TW202130493A; EP4045300A1; US20230025564A1; WO2021122269A1; EP3838576A1

Abstract

A method for manufacturing a wind turbine blade, comprising the steps of: -arranging an upper mould (8) comprising a stack of pre-cast fibres (9 ") on a lower mould (23) comprising a stack of dry fibres (24 ') and a mould core (46), -applying a vacuum to a space (63) between the upper mould (8) and the lower mould (23) and the mould core (46), -infusing at least the stack of dry fibres (24 ') and a connection area (66, 67) between the stack of dry fibres (24 ') and the stack of pre-cast fibres (9") with a resin (65), and curing the resin (65). By having a pre-cast fiber lay-up in the upper mold, encapsulation and positioning of the dry composite on top of the mold core is avoided.

Description

Method for manufacturing a wind turbine blade

Technical Field

The present invention relates to a method for manufacturing a wind turbine blade.

Background

One way to produce more power using a wind turbine under given wind conditions is to increase the size of the blades. However, the manufacture of wind turbine blades becomes increasingly difficult as the size of the blades increases.

Currently, many wind turbine blades are made by: the parts of the prefabricated blade, such as the pressure side shell and the suction side shell, are separated and glued to each other. These parts are prefabricated, for example, by: a composite material such as glass fiber is infused with a resin and the resin is cured. However, the gluing process has a number of disadvantages. For example, it is difficult to achieve sufficient strength and robustness of the glue line. Furthermore, this method requires the precise positioning of very large parts in a limited time, i.e. before the applied glue hardens.

In another method disclosed in EP 1310351 a1, a blade is manufactured by: the composite material for the entire blade or for the longitudinal blade sections is encapsulated on a mandrel and the resin is poured and cured. Thereby, a glued joint is avoided. However, encapsulating and positioning the dry composite on top of a mandrel, which is typically flexible, is challenging, especially for very large blades. Furthermore, as blade size increases, the volume that needs to be filled with resin by vacuum infusion also increases, making resin infusion more difficult.

Disclosure of Invention

It is an object of the present invention to provide an improved method for manufacturing a wind turbine blade.

Accordingly, a method for manufacturing a wind turbine blade is proposed. The method comprises the following steps:

-arranging an upper mould comprising a stack of pre-cast fibres on a lower mould comprising a stack of dry fibres and a mould core,

-applying a vacuum to the space between the upper and lower molds and the mold core,

-infusing at least the dry fibre lay-ups and the connection areas between the dry fibre lay-ups and the pre-cast fibre lay-ups with a resin and curing the resin.

By having a pre-cast fiber lay-up in the upper mold, encapsulation and positioning of the dry composite on top of the mold core is avoided.

Furthermore, precasting the fiber lay-up in the upper mold is preferably done by enclosing the dry fiber lay-up in an inverted upper mold, infusing resin and curing. Since the upper mould is inverted, the encapsulating of the fibre material also takes place in the upper mould towards a mould with a well-defined geometry instead of towards the flexible mould core.

Furthermore, the volume of resin that needs to be filled during vacuum infusion of the dry fibre lay-up and the connection area in the lower mould is smaller with a pre-cast fibre lay-up in the upper mould than with a fibre lay-up that is not pre-cast for the upper part, for the same blade size. Furthermore, the path that the resin needs to travel during vacuum infusion is shorter for the same blade size than if the fibre lay-up was not pre-cast for the upper part. For example, the resin needs to be raised to a lower level above the floor level of the manufacturing site than would be the case if the fiber lay-up was not pre-cast for the upper portion. It is therefore easier to infuse the fibre lay-up with good quality during resin infusion, even in the case of larger blade sizes.

One advantage over the method where the blade parts are glued together is that a laminate joint is provided here which once cured connects the upper pre-cast fibre lay-up and the dry fibre lay-up in the lower mould. The laminate joint formed by resin infusion is a lighter and at the same time stronger joint than a joint using an adhesive. It is lighter because in the case of adhesives, the weight of the adhesive is increased in the bonding line. Furthermore, the strength of the laminate joint formed by vacuum infusion is comparable to the strength of the original laminate. In addition, the laminate joint formed by vacuum infusion avoids the problem of having a glued joint of a different material in the glue than in the rest of the blade.

The wind turbine blade is part of a rotor of a wind turbine. A wind turbine is a device that converts the kinetic energy of wind into electrical energy. For example, a wind turbine includes: a rotor having one or more blades each connected to a hub; a nacelle including a generator; and a tower holding the nacelle at its top end. The tower of the wind turbine may be connected to the foundation of the wind turbine via a transition piece, e.g. a mono pile in the seabed.

The stack of pre-cast fibres in the upper mould becomes the first shell of the blade in the manufactured blade. In particular, it becomes the first half-shell of the blade.

Once poured and cured, the dry fibre lay-up in the lower mould becomes the second shell of the blade in the manufactured blade. In particular, it becomes the second half-shell of the blade.

The first and second shells are in particular fibre-reinforced resin laminates.

The first shell may comprise the pressure side (upwind side) of the blade and the second shell may comprise the suction side (downwind side) of the blade, or vice versa.

The first and second shells may each comprise the entire blade length from the blade root to the blade tip. Alternatively, the wind turbine blades may be divided in the longitudinal direction. In this case, each of the first and second shells comprises a portion of the total length of the blade.

The wind turbine blade, e.g. the root section thereof, is e.g. fixedly connected to the hub. The wind turbine blade is for example bolted directly to the hub.

Alternatively, the wind turbine blade, e.g. the root section, is rotatably connected to the hub. For example, a wind turbine blade is connected to a pitch bearing of the wind turbine, and the pitch bearing is connected to a hub. The pitch bearing is configured to adjust an angle of attack of the blade in accordance with the wind speed to control a rotational speed of the blade.

The wind turbine blade is aerodynamically formed except for a (cylindrical) root section connected to the hub. For example, a wind turbine blade includes a pressure side (upwind side) and a suction side (downwind side). The pressure and suction sides are connected to each other at a leading edge and a trailing edge. The pressure and suction sides and the leading and trailing edges define an interior cavity of the wind turbine blade.

For example, a mold core (or mandrel) includes an inner solid core and an outer flexible portion surrounding the inner solid core.

The core may comprise two or more core parts. Each of the two or more core portions may include an inner, solid core and an outer, flexible portion.

The upper and lower molds and the mold core define a space in which a vacuum for a vacuum infusion process is applied. Resin is infused into the space and partially fills it so as to infuse at least the dry fiber lay-up and the connection region. The pre-cast fiber lay-up is thus impregnated with resin only in the connecting region, whereas the rest of the pre-cast fiber lay-up is not impregnated with resin except in the pre-casting process itself.

The dry fibre lay-up and/or the pre-cast fibre lay-up comprises in particular glass fibres, carbon fibres, aramid fibres and/or natural fibres.

The pre-cast fibres are in particular infused with resin and cured fibres before the step of infusing the dry fibre lay-up and the connecting areas in the lower mould with resin. In other words, the pre-cast fibers in the upper mold are pre-cast and cured in a first wet process (first resin infusion process), and the dry fiber lay-up and the connection areas in the lower mold are infused with resin in a second wet process (second resin infusion process), wherein the first wet process (including curing) and the second wet process are separated in time.

The dry fibre lay-up comprises (only) fibres in dry condition, in particular fibres without resin. The fibers in the dry condition are more flexible than fibers with resin, such as fibers cast in resin or prepreg fibers (prepreg). Encapsulating the fibers in a dry condition into the lower mold or the upper mold allows matching the shape of the respective mold.

The resins include, for example, thermosets, thermoplastics, epoxy-based resins, polyurethanes, vinyl esters, and/or polyesters.

The resin is infused in particular as a result of a vacuum created in the space between the upper and lower molds and the mold core. The resin is cured, for example, by application of heat.

According to one embodiment, the dry fibre lay-up and/or the pre-cast fibre lay-up comprises a fibre core material.

The fibrous core material comprises, for example, wood, balsa wood, PET foam and/or PVC foam.

When the fibre lay-up comprising the core material is infused with resin and cured, a fibre reinforced resin laminate having a core structure made of the core material is obtained. For example, a sandwich structured fibre reinforced resin laminate may be obtained, wherein the core material layer is arranged between the fibre reinforced resin layers.

The dry fibre lay-up and/or the pre-cast fibre lay-up comprises for example an inner laminate and an outer laminate and a core material in between.

Having a fiber core material allows to reduce the weight of the final fiber reinforced resin laminate while maintaining a sufficient stiffness and/or strength of the blade.

According to another embodiment, the connecting region comprises an overlap region in which the pre-cast fibre lay-up and the dry fibre lay-up overlap each other.

Having overlapping areas allows for better bonding of the pre-cast fiber lay-up and the dry fiber lay-up to each other by infusing and curing resin. The resulting joint may better transfer loads in the blade shell.

The overlap area may be smaller than the connection area. Alternatively, the connection region may coincide with the overlap region.

According to another embodiment, the pre-cast fibre lay-up and/or the dry fibre lay-up comprises fibre core material in the overlapping area.

The same structure having a fibre reinforced resin laminate with core material throughout the overlap and join areas allows to obtain a blade shell having homogeneous properties, such as homogeneous strength and weight, across the overlap and join areas.

According to another embodiment, both the dry fibre lay-up and the pre-cast fibre lay-up comprise at least one tapered edge portion overlapping each other in the overlapping area.

Having such tapered edge portions allows for a good overlap of the dry fiber lay-up with the pre-cast fiber lay-up and a smooth transition from one to the other.

According to another embodiment, the pre-cast fibre lay-up and the dry fibre lay-up are in direct contact with each other in the connecting region.

In particular, the surface of the pre-cast fiber lay-up and the surface of the dry fiber lay-up are in direct contact with each other. In the case where the tapered edge portions overlap each other, the inclined surfaces of the tapered edge portions may directly contact each other.

According to another embodiment, an auxiliary material is arranged between a surface of at least one edge portion of the stack of pre-cast fibre plies and a surface of at least one edge portion of the stack of dry fibre plies.

The auxiliary material is for example a non-fibrous material. The auxiliary material is for example a PUR material.

Having this auxiliary material allows in particular to construct more degrees of freedom in the different blade profile profiles to obtain different aerodynamic profiles (airfoils). For example, the secondary material may be applied to form a sharp edge of the aerodynamic profile, such as at the trailing edge of the airfoil.

According to another embodiment, the stack of dry fibers in the lower mold has a main portion within a cavity of the lower mold and at least one extending portion extending from the main portion beyond a side edge of the cavity of the lower mold, and wherein the method comprises the steps of arranging the mold core on the stack of dry fibers in the lower mold and folding the at least one extending portion of the stack of dry fibers onto the mold core prior to the step of arranging the upper mold on the lower mold.

Having this extension and folding it onto the core allows to construct a connecting area offset from the area where the upper and lower mould edges are in contact with each other. Thus, the pre-cast fiber lay-up can be better arranged and positioned on the dry fiber lay-up. Further, the connection region may be configured to be offset from the leading edge and/or the trailing edge, for example. Thus, the connection region may be configured to be offset, for example, from the maximum curvature of the airfoil.

The lower mould comprises in particular a mould cavity for forming and casting a stack of dry fibres. Furthermore, the lower mold comprises horizontal portions extending to the right and left from the side edges of the mold cavity, as seen in cross-section. The mould cavity particularly accommodates a major part of the dry fibre lay-up. The at least one extended portion of the dry fiber lay-up is laid on the horizontal portion of the lower mould, for example before folding it.

According to a further embodiment, a continuous portion of the at least one extension portion has the same layer structure and/or the same thickness as the main portion, the continuous portion being continuous with the main portion.

Said continuity with layer structure and/or thickness from the main portion to the continuous portion of the dry fiber laminate particularly allows to ensure homogeneous properties, such as homogeneous strength and/or weight, of the main portion and the continuous portion. The continuous portion may cover the leading edge and/or the trailing edge of the airfoil. In this way, for example, a homogeneous strength and/or weight of the blade across the leading edge and/or the trailing edge may be ensured.

According to another embodiment, the method comprises, after the step of folding the at least one extension onto the core, the step of fixing the at least one folded extension at the core.

With the extension fixed at the core, the upper mold can be more easily arranged on the lower mold and the core.

The extension is fixed at the mould core, for example by applying a tape, such as an adhesive tape and/or a glass ribbon.

The dry fiber laminate may include two extensions. Each of the two extensions may be secured at the mold core by adhesive tape. Alternatively, the two extensions may be fixed to each other, for example with a tape laid across the core.

According to another embodiment, the method comprises the step of fixing the stack of pre-cast fibre layers to the upper mould before the step of arranging the upper mould comprising the stack of pre-cast fibre layers on the lower mould.

The upper mould comprising the fixed stack of pre-cast fibres can be arranged more easily on the lower mould. This is particularly true when the upper mold is inverted.

The fixing of the pre-cast fibre lay-up can be done by: a foil (foil) is attached to each of the pre-cast fiber stack and the edges of the upper mold, and a vacuum is applied to the space covered by the foil. The fixation may also be accomplished by using elongated elements, such as rods and/or (wooden) sticks clamped to the upper mould, e.g. to the horizontal part of the upper mould. The fixing may also be accomplished by bolting the pre-cast fiber lay-up to the upper mold.

According to another embodiment, the method comprises, before the step of applying a vacuum, the step of covering the mould core with a vacuum bag, and wherein the vacuum is applied to the spaces between the upper and lower mould and the vacuum bag.

Covering the mold core with a vacuum bag may include sealing the vacuum bag. The mould core may also be covered with two or more vacuum bags to increase the tightness.

In this case, the core comprises more than one core part, each of which may be covered with one or more vacuum bags.

In an embodiment, the method may comprise the step of removing the vacuum bag and/or the mould core after infusing and curing the resin. The mould core and/or the vacuum bag are removed, for example, by the blade root section. In this case, the mould core comprises a flexible outer part which can be compressed before the removal of the mould core. For example, a vacuum may be created in the space between the vacuum bag and the mold core, thereby compressing the flexible outer portion and reducing the dimensions of the mold core.

According to another embodiment, the method comprises the step of arranging one or more reinforcing beams on the dry fibre lay-up before the step of arranging the upper mould on the lower mould.

Thus, the one or more reinforcing beams may be cast with the dry fiber lay-up in a wet process, i.e. a infusion and curing process.

The one or more reinforcing beams include, for example, a pressure side beam, a suction side beam, a leading edge beam, and/or a trailing edge beam. The reinforcing beams may be dry-laid layers, pre-cast elements, or a combination of both.

The pressure side beam is in particular a beam on the pressure side of the wind turbine blade. The suction side beam is in particular a beam on the suction side of the wind turbine blade. The leading edge beam is in particular a beam on the leading edge of the wind turbine blade. The trailing edge beam is in particular a beam on the trailing edge of the wind turbine blade.

According to another embodiment, the method comprises the step of arranging a web before the step of arranging the upper mould on the lower mould, and wherein at least the dry fibre lay-up, the connection area and/or the web are infused with resin. One or more webs, for example two webs, may be arranged. In an embodiment, arranging the web comprises arranging a precast web.

Thus, the web can be cast with the fibers in a wet process. The web provides strength to the blade, for example.

According to another embodiment, the web is configured to, once cured, laterally connect the pre-cast fibre lay-up and the dry fibre lay-up within the internal cavity of the blade.

The web is in particular a shear web. The web connects the pressure-side and suction-side blade shells, in particular in the interior of the blade. The web provides shear strength to the blade.

Arranging the shear web and infusing the dry fibre lay-up, the connection region and the shear web with resin allows the shear web to be joined with the upper and lower shells in a single process step by infusing and curing the resin. The shear web may be a dry stack, a pre-cast element, or a combination of both.

Other possible embodiments or alternatives of the invention also encompass combinations of features described above or below with respect to the examples which are not explicitly mentioned herein. Those skilled in the art may also add individual or isolated aspects and features to the most basic forms of the invention.

Drawings

Other embodiments, features, and advantages of the present invention will become apparent from the subsequent description and the dependent claims, taken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a wind turbine according to an embodiment;

FIG. 2 illustrates a cross-sectional view of a pre-cast fiber lay-up forming a first shell of the wind turbine blade of FIG. 1, the pre-cast fiber lay-up being manufactured in an inverted upper mold;

FIG. 3 shows a cross-sectional view of a dry fibre lay-up, once cast and cured, forming a second shell of the blade of the wind turbine of FIG. 1, arranged in a lower mould;

FIG. 4 shows a view similar to FIG. 3, with the mould core and web arranged on the stack of dry fibres in the lower mould;

FIG. 5 shows a view similar to FIG. 4, wherein the extension of the dry fiber stack is folded onto the mold core;

FIG. 6 shows an upper mold with the pre-cast fiber lay-up of FIG. 2 during placement on a lower mold with the dry fiber lay-up of FIG. 5;

FIG. 7 shows a view similar to FIG. 6, wherein the upper mold is arranged on the lower mold, wherein the stack of pre-cast fiber plies overlaps the stack of dry fiber plies in an overlap region;

FIG. 8 shows a view similar to FIG. 7, with resin infused;

FIG. 9 illustrates another embodiment of the overlapping of a pre-cast fiber lay-up with a dry fiber lay-up;

FIG. 10 illustrates another embodiment of the overlapping of a pre-cast fiber lay-up with a dry fiber lay-up; and

FIG. 11 shows a flow chart illustrating a method for manufacturing a wind turbine blade of the wind turbine of FIG. 1.

In the drawings, like reference numbers indicate identical or functionally equivalent elements unless otherwise indicated.

Detailed Description

Fig. 1 shows a wind turbine 1 according to an embodiment. The wind turbine 1 comprises a rotor 2 with one or more blades 3 connected to a hub 4. The hub 4 is connected to a generator (not shown) arranged within the nacelle 5. During operation of the wind turbine 1, the blades 3 are driven by the wind to rotate, and kinetic energy of the wind is converted into electrical energy by a generator in the nacelle 5. The nacelle 5 is arranged at the upper end of a tower 6 of the wind turbine 1. The tower 6 is erected on a foundation 7, for example a mono-pile or a tri-pile. The foundation 7 is connected to and/or driven into the ground or seabed.

An improved method for manufacturing a wind turbine blade 3 is described below with respect to fig. 2 to 11.

In step S1 of the method, an upper mold 8 is provided for precasting a fiber lay-up 9', as shown in fig. 2. Once cured and assembled, the pre-cast fibre lay-up 9 ″ will become the first shell 10 of the manufactured blade 3 (fig. 7). For step S1, the upper mold 8 is inverted, as shown in fig. 2. The cavity 11 of the upper mould 8 encloses the stack 9' of dry fibres. Since the upper mould 8 is inverted, the fibre stack 9' can be enveloped towards a well-defined geometry, in contrast to the situation where the fibre stack is enveloped onto a flexible mould core.

The fibre lay-up 9', 9 ″ in the example of fig. 2 comprises an outer laminate 12 and an inner laminate 13. Furthermore, the fibre lay-up 9', 9 ″ also comprises a core material, for example a balsa core, between the outer laminate 12 and the inner laminate 13. Here it comprises a trailing balsa core 14 and a leading balsa core 15. The outer laminate 12, the

respective balsa cores

14, 15 and the inner laminate 13 form a sandwich structure.

In fig. 2, the fibre lay-ups 9', 9 ″ have a first conical portion 17 and a second conical portion 18 at their left and right edges. In each of these tapered

sections

17, 18, the inner laminate 13, the

respective balsa core

14, 15 and the outer laminate 12 are tapered. Thus, the

tapered portions

17, 18 each have a continuous

inclined surface

19, 20.

The fibre lay-ups 9', 9 "in fig. 2 also comprise precast beams 16. The beam 16 is, for example, a suction side beam or a pressure side beam of the blade 3.

The dry fibre lay-up 9' is pre-cast by a known vacuum infusion process as described in EP 1310351 a 1. During this vacuum infusion process, the fibre lay-up 9' is covered with a vacuum bag (not shown) and the vacuum bag is sealed (not shown) at the

horizontal portions

21, 22 of the upper mould 8. Furthermore, a vacuum is created in the space covered by the vacuum bag, and resin (not shown) is infused into the fibre lay-up 9' and cured, resulting in the pre-cast fibre lay-up 9 ″ shown in fig. 2.

In step S2 of the method, a lower mold 23 is provided, as shown in fig. 3. The lower mold 23 encloses a stack 24' of dry fibers.

The dry fiber stack 24' includes an outer laminate 25 and an inner laminate 26. In addition, the dry fiber laminate 24' includes core materials, such as leading edge balsa core 27 and trailing edge balsa core 28. The fibre lay-up 24' thus has a sandwich structure, in which the respective

balsa wood cores

27, 28 are sandwiched between the outer laminate 25 and the inner laminate 26.

The fiber lay-up 24' also includes a precast beam 29. The beam 29 is, for example, a pressure side beam or a suction side beam of the blade 3.

The lower mold 23 includes a mold cavity 30 and

horizontal portions

31, 32 extending from side edges 33, 34 of the mold cavity 30.

By disposing the main portion 35 of the dry fiber laminate 24 'within the cavity 30, the dry fiber laminate 24' is encapsulated into the lower mold 23. In this example, the main portion 35 includes a first main portion 36 and a second main portion 37. The first main portion 36 is arranged to the left in fig. 3 of the beam 29. The second main portion 37 is arranged to the right in fig. 3 of the beam 29.

Furthermore, the

extension portions

38, 39 of the dry fiber lay-up 24' extend from the main portion 35, i.e. from the first main portion 36 and the second main portion 37, respectively, beyond the side edges 33, 34 of the cavity 30.

The extension portion 38 includes a first continuous portion 40 and a first tapered portion 42. The extension portion 39 includes a second continuous portion 41 and a second tapered portion 43.

In this example, the continuous portion 40 has the same layer structure of the outer laminate 25, leading edge balsa core 27 and inner laminate 26 as the first main portion 36 of the fibre lay-up 24'. Furthermore, the continuous portion 40 has the same thickness d1 as the first main portion 36. Furthermore, the continuous portion 41 has the same layer structure of the outer laminate 25, the trailing balsa core 28 and the inner laminate 26 as the second main portion 37 of the fibre lay-up 24'. Furthermore, the continuous portion 41 has the same thickness d2 as the second main portion 37.

In each of the first and second

tapered portions

42, 43, the inner laminate 26, the

respective balsa core

27, 28 and the outer laminate 25 are tapered. Thus, the

tapered portions

42, 43 each have a continuous

inclined surface

44, 45.

In step S3 of the method, a mold core 46 is disposed on the stack of dry fibers 24', as shown in fig. 4. The core 46 comprises a first core part 47 and a second core part 48. For example, each of the first and

second core portions

47, 48 includes a strong

inner core

49, 50 and a flexible

outer portion

51, 52. For example, the flexible

outer portions

51, 52 comprise a compressible foam material.

Before arranging the

core parts

47, 48, each of them is covered with a

vacuum bag

53, 54, as shown in fig. 4. The

vacuum bags

53, 54 are sealed.

In step S4 of the method, a shear web 55 is provided on the dry fiber stack 24' and between the first and

second core portions

47 and 48. In the example shown in the figures, the web 55 is a dry laminate. In other examples, the web 55 may also be pre-cast.

Step S4 may be performed simultaneously with step S3 of arranging the

core parts

47, 48.

In step S5 of the method, the

extended portions

38, 39 of the stack 24' of dry fibers are folded onto the respective first and

second core portions

47, 48 of the core 46, as shown in fig. 5.

In step S6 of the method, the

extension portions

38, 39 are fixed to the respective first and

second core portions

47, 48. In detail, the extension 38 is fixed to the first core part 47 covered with the vacuum bag 53 by means of a first adhesive tape 56. Furthermore, the extension 39 is fixed to the second core part 48 covered with the vacuum bag 54 by means of a second adhesive tape 57.

In step S7 of the method, the stack of pre-cast fiber plies 9 ″ pre-cast in the upper mould 8 in step S1 (fig. 2) is fixed to the upper mould 8. For example and as shown in fig. 6, the stack of pre-cast fiber layers 9 "is fixed to the upper mold 8 by means of attaching a first foil 58 and a second foil 59 to the stack of pre-cast fiber layers 9" and the upper mold 8, respectively. The foils 58, 59 are sealed. Fig. 6 illustrates an exemplary seal 60. In the space covered by the foils 58, 59 a vacuum is created which holds the stack 9 ″ of pre-cast fibres in the upper mould 8 and in the next step rotates it and lowers it onto the lower mould 23.

Steps S1 and S7 may be performed before steps S2 to S6, simultaneously with steps S2 to S6, or after steps S2 to S6.

In step S8 of the method, the upper mold 8 is arranged on the lower mold 23, as shown in fig. 6. Arranging the upper mould 8 on the lower mould 23 comprises turning the upper mould 8 from the position in fig. 2 to the position in fig. 6. Fig. 6 shows the following state, namely: in this state, the fibre lay-up 9 ″ has been fixed to the upper mould 8, and the upper mould 8 is raised, turned over and lowered onto the lower mould 23.

Fig. 7 shows a state in which the upper mold 8 has been arranged on the lower mold 23. The stack of pre-cast fibers 9 "and the stack of dry fibers 24' overlap each other in both the first and second overlapping

areas

61, 62. Fig. 7 shows an inset with an enlarged view of the overlap region 61. In particular, the tapered portion 18 of the pre-cast fiber lay-up 9 ″ and the tapered portion 42 of the dry fiber lay-up 24' overlap each other in an overlap region 61. Thereby, the inclined surface 20 of the tapered portion 18 and the inclined surface 44 of the tapered portion 42 are in direct contact with each other.

Similarly, the tapered portion 17 of the stack of pre-cast fiber plies 9 ″ and the tapered portion 43 of the stack of dry fiber plies 24' overlap each other in an overlap region 62. Thereby, the inclined surface 19 of the tapered portion 17 and the inclined surface 45 of the tapered portion 43 are in direct contact with each other.

In this example, as can be seen in the inset of fig. 7, the layer structure of the pre-cast fibre lay-up 9 ″ comprising the outer and

inner laminates

12, 13 and the

respective core materials

14, 15 matches the layer structure of the dry fibre lay-up 24' comprising the outer and

inner laminates

25, 26 and the

respective core materials

27, 28.

In step S9 of the method, a vacuum is created in the space 63 defined by the upper and

lower molds

8, 23 and the

vacuum bags

53, 54 covering the

core portions

47, 48, as shown in fig. 8.

In step S10, the resin 65 is introduced into the space 63. In particular, the resin 65 is introduced into that part of the space 63 which comprises the dry fibre lay-up 24', the

connection regions

66, 67 and the web 55. For example, the resin 65 is introduced by a vacuum infusion process, such as Vacuum Assisted Resin Transfer Molding (VARTM). For further details of the generation of the vacuum, the infusion and curing of the resin 65, reference is made to EP 1310351 a 1.

The example shown in the figure shows the case where the web 55 is a dry laminate. In this case, the web 55 is completely impregnated with resin 65, as shown.

In other examples, a precast web may be used in place of web 55. Resin 65 will then be infused only in the upper and lower connection portions of the web (i.e., in the areas where the web will be connected to beam 16, and in the areas where the web will be connected to beam 29), but not in the vertical portions of the web.

Fig. 8 shows an exemplary inlet channel 64 through which resin 65 is poured. With the introduced resin 65, the dry fiber lay-up 24', the connection areas 66, 67 (between the dry fiber lay-up 24' and the pre-cast fiber lay-up 9 ″), and the web 55 are cast in a single processing step.

Each of the

connection regions

66, 67 comprises in particular a

respective overlap region

61, 62. In this example, the

connection areas

66, 67 are respectively larger than the

overlap areas

61, 62. In another embodiment, the

connection areas

66, 67 and the

overlap areas

61, 62, respectively, may be identical.

Since the fibre lay-up 9 "in the upper mould 8 is pre-cast, the resin 65 only needs to fill the dry fibre lay-up 24', the

connection areas

66, 67 and the web 55, and not the rest of the pre-cast fibre lay-up 9", during the vacuum infusion process in step S9. Therefore, the resin 65 needs to travel a shorter path and fill a smaller volume than if the fiber lay-up in the upper die 8 were in a dry condition, i.e. no resin.

In step S11, the infused resin 65 is cured by known processes to obtain a cured and assembled blade shell. As shown in fig. 8, the pre-cast fibre lay-up 9 "in the upper mould 8 becomes the first half shell 10 in the manufactured blade 3. Furthermore, once poured and cured, the fibre lay-up 24 "in the lower mould 23 becomes a second half shell 68 in the manufactured blade 3. Once cured, the web 55 connects the first half-shell 10 and the second half-shell 68 laterally within the internal cavity 71 of the blade 3.

In this example, the resulting fibre reinforced resin laminate of the

shell

10, 68 has the same structure, including the

inner laminate

13, 26, the

core material

14, 15, 27, 28 and the

outer laminate

12, 25 throughout the

overlap areas

61, 62 and the

connection areas

66, 67. Thus, a blade 3 is obtained having a shell with homogeneous properties, such as homogeneous strength and weight, across the overlapping and connecting

areas

61, 62, 66, 67.

In step S12 (not shown), the

core parts

47, 48 and the

vacuum bags

53, 54 are removed from the blade 3, for example by the root section of the blade 3.

With this method a blade is manufactured, wherein the first and

second shells

10, 68 are connected to each other by a laminate joint which is light and at the same time a strong joint.

In another embodiment, as shown in fig. 9, the overlapping region 161 of the pre-cast fiber lay-up 109 "in the upper mold 108 and the dry fiber lay-up 124' in the lower mold 123 is free of

core material

115, 127. Thus, in the overlap region 161, the outer and

inner laminates

112, 113 of the pre-cast lay-up 109 "overlap with the outer and

inner laminates

125, 126 of the fibre lay-ups 124', 124" in the lower mould 123. However, the core material 115 of the pre-cast fiber lay-up 109 "does not overlap with the core material 127 of the fiber lay-ups 124', 124" in the lower mold 123.

In another embodiment, as shown in fig. 10, the secondary material 69 is provided in the overlap area 262 of the pre-cast fiber lay-up 209 "in the upper mold 208 and the fiber lay-ups 224', 224" in the lower mold 223. For example, the auxiliary material 69 is a PUR material. Which is applied in the example of fig. 10, for example to form a sharp edge 70 of the aerodynamic profile of the blade 3 at the trailing edge of the airfoil.

The auxiliary material 69 is in the example of fig. 10 arranged between the inclined surface 219 of the tapered edge portion 217 of the pre-cast fibre lay-up 209 "and the inclined surface 245 of the tapered edge portion 243 of the fibre lay-up 224', 224" in the lower mould 223. Furthermore, the micro webs 229 are arranged to connect the pre-cast fibre stack 209 ", the secondary material 69 and the fibre stacks 224', 224".

While the invention has been described in terms of preferred embodiments, it will be apparent to those skilled in the art that modifications are possible in all embodiments.

Claims

1. A method for manufacturing a wind turbine blade (3), comprising the steps of:

-arranging (S8) an upper mould (8) comprising a stack (9 ' ') of pre-cast fibres on a lower mould (23) comprising a stack (24 ') of dry fibres and a mould core (46),

-applying a vacuum (S9) to the space (63) between the upper and lower molds (8, 23) and the core (46),

-infusing (S10) at least the dry fibre lay-up (24 ') and the connection area (66, 67) between the dry fibre lay-up (24') and the pre-cast fibre lay-up (9 ") with a resin (65), and curing (S11) the resin (65).

2. Method according to claim 1, wherein the dry fibre lay-up (24') and/or the pre-cast fibre lay-up (9 ") comprises a core material (14, 15, 27, 28).

3. Method according to claim 1 or 2, wherein the connection region (66, 67) comprises an overlap region (61, 62), in which overlap region (61, 62) the pre-cast fibre lay-up (9 ") and the dry fibre lay-up (24') overlap each other.

4. A method according to claims 2 and 3, wherein the pre-cast fibre lay-up (9 ") and/or the dry fibre lay-up (24') comprises the core material (14, 15, 27, 28) in the overlap region (61, 62).

5. Method according to claim 3 or 4, wherein both the dry fibre lay-up (24') and the pre-cast fibre lay-up (9 ") comprise at least one tapered edge portion (17, 18, 42, 43) overlapping each other in the overlapping area (61, 62).

6. Method according to any one of claims 1 to 5, wherein the pre-cast fibre lay-up (9 ") and the dry fibre lay-up (24') are in direct contact with each other in the connection region (66, 67).

7. Method according to any one of claims 1-5, wherein an auxiliary material (69) is provided between a surface (219) of at least one edge portion (217) of the pre-cast fibre lay-up (9 ") and a surface (245) of at least one edge portion (243) of the dry fibre lay-up (24').

8. The method according to any one of claims 1 to 7, wherein the stack (24') of dry fibers in the lower mould (23) has a main portion (35) within a cavity (30) of the lower mould (23) and at least one extending portion (38, 39) extending from the main portion (35) beyond a side edge (33, 34) of the cavity (30) of the lower mould (23), and wherein the method comprises the step of arranging (S3) the core (46) on the stack of dry fibers (24 ') in the lower mould (23) and folding (S5) the at least one extension (38, 39) of the stack of dry fibers (24') onto the core (46) before the step of arranging (S8) the upper mould (8) on the lower mould (23).

9. Method according to claim 8, wherein a continuous portion (40, 41) of the at least one extension portion (38, 39) has the same layer structure and/or the same thickness (d 1, d 2) as the main portion (35), the continuous portion (40, 41) being continuous with the main portion (35).

10. Method according to claim 8 or 9, comprising the step of fixing (S6) at the core (46) at least one folded extension part (38, 39) after the step of folding (S5) the at least one extension part (38, 39) onto the core (46).

11. The method according to any one of claims 1 to 10, comprising the step of fixing (S7) the stack of pre-cast fibre layers (9 ") to the upper mould (8) before the step of arranging (S8) the upper mould (8) comprising the stack of pre-cast fibre layers (9") on the lower mould (23).

12. Method according to any of claims 1 to 11, comprising the step of covering the mould core (46) with a vacuum bag (53, 54) before the step of applying a vacuum (S9), and wherein the vacuum is applied to the space (63) between the upper mould (8) and the lower mould (23) and the vacuum bag (53, 54).

13. The method according to any one of claims 1 to 12, comprising the step of arranging one or more reinforcing beams (29) on the dry fibre lay-up (24') before the step of arranging (S8) the upper mould (8) on the lower mould (23).

14. The method according to any one of claims 1 to 13, comprising the step of arranging (S4) a web (55) before the step of arranging (S8) the upper mould (8) on the lower mould (23), and wherein at least the dry fibre lay-up (24'), the connecting areas (66, 67) and the web (55) are infused (S10) with resin (65).

15. A method according to claim 14, wherein the web (55) is configured to connect the pre-cast fibre lay-up (9 ") and the dry fibre lay-up (24', 24") laterally within the internal cavity (71) of the blade (3) once cured.